In 2004, Chris started as a driller’s assistant with Drillcorp at Sunrise Dam, drilling initial diamond coring holes at Tropicana mine when it was still an exploration site, before moving onto deep directional drilling programs at Leonora and Forrestania. In 2006, Chris joined Boart Longyear (BLY) initially as a driller, before moving into a supervisory role at BHP Billiton’s Leinster and Mt Keith operations. This was when Chris developed a thorough appreciation of industry safety, and he’s grateful for the front row seat during a notable period of change in safety systems and workplace cultural maturity. In 2014, the Great Financial Crisis adversely impacted Australia’s mining and exploration with widespread reduction across all surface drilling. Chris was redirected to BLY’s Waterwell division across multiple Pilbara sites. Chris eventually returned to the Goldfields to assume a regional supervisor role before being rewarded with his current role as operations manager for BLY’s underground division, APAC.

Chris Hopkins: My father worked within Chevron’s lubrications business, collecting many small-scale models of heavy mining equipment. As a kid, I was fascinated by his ‘toys’ – sparking my interest and a subsequent stream of questions to my patient, receptive Dad who has since retired. I greatly admire my Dad for his genuine want to be of value to his community and local church. At age 24, I became a father for the first time while working in the liquor industry and wanted to veer to an industry where hard work, commitment and dedication were appreciated. I was also itching for adventure and a change in scenery, having been inside a lively wine store for too long. The prospect of working in the great outdoors at remote locations, being physical, and solving mechanical issues really appealed, so I made the switch.

CH: My professional role models and mentors include the esteemed and respected likes of Dale Barron, Des Forde, Gregor Stephenson, the late John Emerson, and Murray Hillier. Their collective drilling knowledge, willingness to engage and educate, while offering support has had the most profound effect on my career.

CH: I can’t recall a specific moment or project, as I’ve enjoyed many adventures during my career. Drilling challenges me on so many levels – from working and living away in remote locations and interesting environments, to geological undertakings through difficult formations, and the eventual satisfaction of completing a deep directional drilling program. In true A-type style, I beam with unwavering pride when my rig, fleet and team present well and drill effectively.

CH: 1. Good work habits and a positive mental attitude: the underground space is a very physical and challenging workplace, but it’s also a great place to work – I love it! Every task has an exacting set of measures which must be followed, as short cuts are not tolerated. Determination and attention to detail is necessary given the restricted work areas, equipment limitations and specific underground drilling requirements that can vary from +90 to -90 degrees. Excellent communication is paramount as daily interaction with mining teams is necessary to deliver quality samples within specific time frames. It is quite common for a mining team to immediately assume an area once drilling is complete.

2. Safety culture maturity: we must respect and understand our working environment, and maturity toward safety is a prerequisite to the underground mining sphere, given the inherent risk in what we do. I cannot and will not tolerate immaturity or lack of focus as either will result in someone being hurt and equipment being damaged.

3. People: are the most important and defining facet to success – in any industry. People who genuinely care and take pride in their work and accomplishments are who you want on your team. I’ve been fortunate to have worked with talented and capable people, and I’m most proud of my current team – they are enthusiastic, professional, highly motivated and experienced. We’ve developed an amazing and supportive working culture as a result.

CH: My somewhat cheeky response is whatever drilling type I’m currently focused on and involved in. Seriously, every discipline – underground or surface drilling has its own challenges including ground conditions, technical drilling requirements to achieve targets, underground grade control programs requiring multiple rig locations and set-ups per shift, to large diameter holes requiring large tooling to complete. The challenge of individual hole completion is what deems the drilling industry such an exciting business to work in. Up-hole drilling is a constant challenge, as underground geology departments strive to keep costs down. Sometimes the only way or location to achieve target is to drill ‘up’. Boart Longyear’s Roller Latch system allows crews to successfully and safely do so while following best drilling practices.

CH: Underground mining and drilling teams work closely, attending the same pre-start meetings and engaging more frequently than would occur at surface. When underground, everyone is under the supervision of the shift boss and underground mine manager, with increased engagement with the mining safety team. My drilling team has forged greater cohesion between the two groups, implementing exemplary practice and innovation that has been adopted by all, and I couldn’t be prouder.

CH: There are two reasons – risk and cost. Drilling is dangerous especially when poorly managed, so it makes sense to hire a professional contractor to complete the work. Contractors must be accountable and continually improve to secure future work. A lot of effort goes into delivering safe, seemingly hassle-free (for the client) drilling. Then there is cost. Most mining companies are incapable of cost-effective and productive in-house drilling. Contractors remain focused on achieving safe and productive outcomes for their ongoing financial survival and reputation.

CH: Delays associated with mine blasting and other mining activities significantly reduce the amount of time drilling crews must complete work, while eliciting an added expense to the client. BLY’s Drill Control Interface (DCi) system enables continuous drilling, even while the rig is unattended. Semi-autonomous capability within the underground drilling space is subject to an anticipated transformation, and it’s an exciting time. Many mines have, and continue to install underground Wi-Fi communication systems for enhanced communication between the drill crew and surface-based support crew.

CH: The underground space is in need of innovation, and Boart Longyear’s dynamic approach has meant that I’ve been involved in the development and release of some of the industry’s leading improvements including Roller Latch, diamond coring bits – designed and tested in the field by our drillers, and safety improvements to both drilling equipment and in the field training systems. Our fleet features machines that enhance the driller interface with improved safety and increased performance thanks to BLY’s ability to design and manufacture reliable rigs and drilling equipment, backed by adept and supportive maintenance teams, and an extensive global supply chain. I’m particularly excited about current innovations and advancements we expect to release within the next year. I can’t elaborate just yet, so watch this space.

CH: Most Australian underground drilling is N-size as it yields clients respectable sized core samples for the cost. For drilling contractors, N-size improves productivity with wireline systems, reduces manual handling when compared to conventional systems, and improves hole completion in poor formations. Boart Longyear’s Roller Latch system also provides much safer operations when drilling up holes, veering away from conventional processes.

CH: The potential to intercept an underground water source when drilling underground is both great, and undesirable. Thorough planning, detailed risk assessment and experience round out the high-pressure prevention trifecta, coupled with having the necessary tooling at the ready – should it be required.

CH: Drilling fluids are critical to hole completion in broken, unstable or pressurized formations – supporting all aspects of hole conditioning from reducing torque, assisting in the removal of cuttings, increasing hydrostatic pressure, stopping hydro sensitive formations from reacting, and some products hold together loose formations. Cost is critical and all staff – not just drilling crews must be educated as to correct usage to ensure zero to minimal wastage as this can greatly affect cost per meter. Reliable terminal equipment is key to ensure the most time down the hole. I’ve encountered many holes where formation stability is greatly reduced due to tripping of rods or introducing unnecessary pressures onto the formation, leading to extensive hole cleaning which then increases the likelihood of an unsuccessful hole completion.

CH: Boart Longyear makes use of wedging in both surface and underground operations. Wedging needn’t be a safety concern if effective planning and good communication are upheld. Importantly, we work closely with our clients to ensure this is the best option for them, as the cost to drill a new hole within the underground space can be cheaper than attempting directional drilling.

CH: Cementing works best when it is kept simple, checking everything twice. Like the carpentry adage, ‘measure twice; cut once.’ Training is key – as it is with all aspects of drilling. Be mindful of setting and correctly calculating grout volume. Other points to note: is the cement type correct or best suited to the formation? Is the product within its best before date, and has it been stored correctly? Are the slurry volume calculations correct? Is the potential for contamination being limited while mixing and displacing slurry? Be sure to extract a slurry sample to reference. Importantly, if you’re using an additive, be sure to follow the manufacturer guidelines as more is not always better. Lastly, don’t feel pressured when attempting as this is when most mistakes do occur. In Australia, we use VAN RUTH® cementing plugs as they’re a proven product that work well.

CH: Lack of preparation. A driller’s day starts with the all-important pre-start meeting, where supervisors outline and ensure that their teams understand what is expected to occur during that shift. Appropriate and reliable equipment is made available for the crew to safely complete every task and activity. Rushing to complete a job, particularly due to failure to plan, or lack of preparation is a recipe for disaster – namely injury.

CH: I’ve been fortunate to have been involved in many deep directional drilling programs throughout Western Australia, however, it’s important to note that this drilling method varies from production-based drilling within the underground space. The focus is on hole completion and hitting the desired target. It’s complex, extremely technical, and requires intensive supervision, as every decision affects how the hole is drilled from start to finish. I enjoy drilling at depth – the planning, preparation, and necessary attention to detail (correct choice and use of equipment, barrel configurations and monitoring the hole’s deviation) to achieve target. It’s a proud moment to be part of a team that successfully reaches end of hole, delivering a sample of an ore body to a client from over 2000-meters depth.

CH: Directional drilling using down hole motors is an effective method to hit multiple targets from a ‘parent’ hole. The method is best applied to deeper targets and areas where the cost to drill through waste rock exceeds the cost to complete the directional requirements to reach the targeted zone.

CH: The survey industry and its products are rapidly advancing in capability and reliability, with fantastic products available. Most importantly, the system must meet client requirements and be easy to operate, with flexibility for drilling teams to utilize tools to maintain effectiveness. I’m a firm advocate of the Azimuth Aligner® as it reduces rig set up time and relieves pressure on mine survey teams.

CH: Mining is critical to Australia’s economy, and every operation has been closely monitored to eliminate or minimize risk. Australia truly is the ‘lucky country’ for a few reasons – our geographic isolation and relatively small population combined with our swift acting government’s measures (international and state border lockdowns and mandatory 14-day self-isolation), has so far protected us as a nation. Over 25 million people live in Australia, yet our death rate from the pandemic is deemed low – just over 100 people. We must never be complacent and we’re mindful of the much talked about second and third phases, hence Australia’s strict border controls.

CH: Exciting technologies are being harnessed and adapted within diamond drilling. Many contractors are relentless in their pursuit to remove manual handling for a twofold result – eliminate and minimize injuries, while encouraging the broader community to consider the profession. Drilling cannot occur without people and the industry benefits when dedicated, focused and diligent people continually strive to improve perception and conditions. People are the future of drilling, so we must ensure that our industry evolves with safety, education, innovative systems and solutions at its forefront, as evidenced by key groups such as Australian Drilling Industry Association (ADIA) – endeavoring to improve standards and protocol for collective success – now and in the future. I’m currently involved at a research and development level, applying expert advice and feedback to hone various soon-to-be-released Boart Longyear equipment and tools that will greatly improve safety and productivity, while questioning how we approach drilling. It’s an incredibly exciting time to be in the industry and I personally cannot wait to see it come to fruition. Watch this space!

Spell out key aspects of the project timing and any key milestones. Do federal (national) or state (provincial) permits only allow the drilling contractor on site at certain times or durations? Are there exceptions in the permit due to habitat/breeding concerns with local wildlife? Will site access become problematic during a change in weather, ie. rain, snow, heat? If site access is only helicopter accessible, are there firm start and end dates? Are the dates pertaining to any site visits, question periods, tender submission, and project award clearly spelled out? 

There are many variables that contribute to the overall success of a drilling program. Setting clear expectations around anticipated penetration rates (if applicable, historic rates are best), acceptable core recovery percentage, drilling accuracy/hole deviation, survey intervals, core orientation, consumable supplies, sample storage / core boxes, water sourcing and transport, automated rod handling, accommodations for geotech support, etc. provides those bidding the work with consistent information, allowing a better value comparison in the end. Failing to define expectations often leads to operational confusion, delays, cost overruns, change orders, and future discussion around cost containment. No one wants their program shortened because time and money were wasted resolving issues that could have been clarified up front.

Unique site conditions can make or break a project. Understanding your permit and the applications to your drilling program are paramount. Requirements for water usage and drilling fluid disposal are vitally important. A drilling contractor can incur significant additional costs to complete a drilling project if drilling fluid management is not clear in the RFQ. Many drilling projects are now moving to drilling fluid management systems that produce a semi-dry solid and do not put any drilling fluid on the ground or in an onsite pit. What about noise? Are there requirements regarding wildlife disturbance, breeding periods, migration areas, nearby housing, or other potential issues where noise from the drilling activities on the site would impact a drilling contractor’s ability to operate?

Site disturbance has also become an increasingly important issue as it is typical for permits to only allow so many acres of active disturbance prior to reclamation activities. Given your site locations, how many active sites can you have with proper regard to safe operations?

Clearly defined travel routes to the drilling locations and laydown areas as well as expectations about off-road travel and potential one-off events are important and best sorted prior to bid submission so that all the potential service providers know what is required. Many contractors have seen instances where the drilling crews identify alternate travel routes, for various reasons, that do not meet project or permit expectations.

During the bidding process it is inevitable that questions will arise no matter how well the RFQ has been prepared. Having a clearly identified team and communication process speeds up resolution and keeps all the bidders on the same page. Identifying representatives from Geology, Hydrology, Health and Safety, Engineering, and Supply Chain/Procurement and having them in the loop on the project specifications assists potential bidders in getting questions answered and any necessary clarifications made easily and quickly.

Be clear about non-conforming bids. Will they be accepted and considered?  Accepting a non-conforming bid that may seem to provide a better value often ends up adding confusion to the decision-making process by straining accurate comparisons between contractors and lengthening the tender process through additional questions and needed clarifications. Take the time to be thorough up front and the outcome will be better served without wasting time trying to sort out how to compare a non-conforming tender.

At the end of the day, a strong contract is the best way to guarantee project success and if things get off track, it provides a clear backstop to discussions and issue resolution. Thinking through the key aspects of the program and vetting ideas and mitigation plans prior to issuing the RFQ results in bid submissions aligned to your expectations, allows for easier comparison among contractors, and keeps your project timing and costs on track from day one. Happy Drilling!

For example, consider the first exploration drilling project that might take place on Mars. New variables such as lack of oxygen, space travel, and extreme climates make for a difficult work environment and unfamiliar conditions. But at the end of the day, what’s most important is a drill teams’ ability to communicate effectively throughout the duration of the project.

Regardless of the place or world where a drilling project is located, success starts and finishes with communication. 

Consider projects you have completed… how did communication affect the outcome?

Because we interact and associate with people every day, communication can often be overlooked as an essential factor of success. Here are seven tips for effective communication to help keep your team in check, and ultimately exceed project goals and objectives.

Onsite team communication starts with all members understanding the chain of communication. During the drilling process, communication starts and stops at the driller’s controls. The driller is responsible for   all procedures and tasks on the job site, and is aware of every process. The driller also prioritizes tasks and communicates this to the entire team.

This chain of communication works because the drill crew knows the driller is the starting point for every process. The driller is the first to observe changes downhole communicated by the drill rig and the tooling, and then he/she transfers critical information to the rest of the onsite team. 

In the past, it was not uncommon for the supervisor (foreman), driller, and the driller assistant to be the only crew members to understand the drilling process. The rest of the drill crew was only expected to understand the job site specific daily tasks, and general safety requirements.

The old-world argument warns that educating all members onsite can lead to the possibility of leaking job site information and trade secrets to the competition. This antiquated way of operating created an information silo of many under-invested employees.

A 21st-century drilling team understands that it’s more important to hire team members who exhibit honesty and integrity, increasing the level of trust and ensuring critical information remains safe.

Furthermore, a thoroughly educated drill team can interpret and react faster to a drill rig’s communication. These teams anticipate catastrophic rig failures or downhole issues and implement corrective measures. When a drill team is properly trained and understands the drilling process, its members can safely take preventative action to minimize problem events that could potentially impact the project. 

Aligning communication starts with all members onsite utilizing common job site terminology and safety language. That language changes depending on the region, rig manufacturer, and level of the crew’s professionalism.

Consider the four-letter word “STOP!”; it’s not uncommon for a drill crew from Wyoming full of horsemen to use another four-letter word “WOAH!” Both terms meaning, ‘halt all activities’ can be utilized safely when team members are aware of both interpretations and use.

Often 80% of all correspondence on a noisy construction site is non-verbal signals. Hand signals are also a beneficial form of communication if everyone is employing the same signs. Operators, along with spotters, must be able to see and signal each other when it’s challenging to hear verbal commands. An experienced drill team can operate safely and effectively for hours on site while speaking very few words and utilizing industry standard hand signals. Crews that use hoisting and heavy equipment operation signals have much lower near-miss and recordable incident rates than crews that use random hand signals like waving to one another. 

Effective external communication starts with knowing which type of customer is being engaged and what information they require. This dynamic changes due to confidential information. The project information relayed to the senior geologist or the project customer will rarely be the same as the information given to the neighboring landowner or the local public.

A drilling crew should have a defined communication plan that starts with asking who the visitor is, so they can understand why they are onsite, followed by directing the visitor to the right representative. The big fear is that ‘the new guy’ might relay incorrect data to the customer or pass on confidential information to a stranger. This is why it’s essential to have a strategic plan for external communications and remind the onsite drilling team of that communication plan daily.

On a “right-of-way project,” good communication begins with the team knowing all abnormal operating conditions for environmental, health, and safety (EHS) considerations and adherence.

An abnormal operating condition could be anything from an environmentally sensitive area, which would limit the hours of operation for equipment that reaches over 80 decibels of noise. If a rancher arrives onsite at dark with a flashlight saying that the drill is interrupting his livestock’s sleep, it is crucial to know the rules before engaging with him. 

Often on an established drilling site, this information is presented as a site-specific orientation by the customer. However, on smaller single-hole projects, the only EHS information is found in the contract.

Drilling is a disruptive process that changes the location forever. Once a drill starts cutting the ground, the chain of communication quickly expands from the customer, to possibly the neighboring property owner, to corporate officials, to regulatory government agencies. Each party requires different information to properly oversee job completion.

Complex projects in remote locations require a diverse staff of people to complete the job successfully. The men and women involved have a common goal of success, however, they have individual objectives and information to gather before the job is complete. When all parties involved understand their goals, and the goals of others through proper communication, project success increases exponentially.

Effective communication is fully understanding what is being said before answering. It’s easy to assume what information the customer wants and have a response ready, but often crucially relative information is lost while listening to respond.

Effective communication requires all parties on a project work together for best results. At the Advanced Rig Technology Conference hosted by the IADC, presenter David Kaplan, a NASA Engineer, spoke about the importance of NASA continuing to utilize pilots when moving humans in and out of space.

He said “You can’t engineer man out of the technology. It will cost you billions of dollars. However, the goal is to give them the right information through effective communication at the right time to make the best decision.”

NASA understands that men and women with the right information, working in collaboration with their team, can outperform and overcome any situation. Communication requires cooperation to be effective just as a drilling project can only be successful when the drill team, customer, neighbor, and regulator all work together.

Our host, Jon Peterson (Geo Jon for fun), works for the Products division as a Customer Service Representative. Jon graduated from the University of Utah in 2015 with his Bachelors of Science in Geology. He’s worked for Boart Longyear for the last two and a half years and interned as a geologist with an exploration company for about six months prior to coming to work for Boart Longyear. Jon has been married for a year and a half and in his free time enjoys trail running, hiking, working on his yard, spending time with family, and playing with his black lab Dexter. 

We would love to hear your questions and comments below. Thanks for listening and if you liked this episode, share it on LinkedIn, Facebook, or Twitter. 

In July, Vice President of Global Engineering Shayne Drivdahl discussed how Boart Longyear’s engineering team might be one of the company’s best-kept secrets. Providing a variety of professional drilling services to exploration and mining companies, the Company also designs, manufactures, and sells reliable drilling rigs, quality tooling, and accurate instrumentation.

Thanks to its team of engineers located throughout the world, the company is able to develop products and put them through rigorous testing in the hands of its own Drilling Services personnel. Tools and equipment are not only tested in the lab but also in the field. The collaboration between members of the global engineering team and Boart Longyear’s drillers elevates the performance of both Boart Longyear Drilling Products and Boart Longyear Drilling Services. Read the full article to learn more about the beneficial synergy gained between the two divisions.

In July, Design Engineer Anthony Lachance wrote about the newest developments and early testing results from the Roller Latch Overshot. Since Boart Longyear introduced the Q Wireline system in 1966, retrieving the inner tube from the core barrel has been handled the same way: an overshot with lifting dogs (spring loaded hooked “fingers”) is lowered or pumped into the hole until it snaps over a pivoting spearhead mechanism affixed to the inner tube assembly. Once the head assembly has been removed from the hole, the driller uses the pivoting spearhead to position the head assembly on their workspace and squeezes the back of the lifting dogs to release.

Since being introduced, this system has had the same basic issues. Learn how Boart Longyear’s new Roller Latch^TM Overshot has been highly anticipated and how drillers are noting the various positive developments: it’s easier to use, saves on wireline, and makes working with Q/P Roller Latch head assemblies much easier in difficult conditions.

In March, Global EHS Manager Brian Maeck introduced us to the Boart Longyear Glove Matrix. More and more mining and drilling companies are developing automation technologies to improve employee safety and efficiency. However, there are still plenty of risks for the hard-working hands of drillers: pinch points, sharp edges, rotating equipment, chemicals, etc. Hand injuries are still one of the most common and preventable injuries.

Along with following safe practices like using a risk assessment prior to any task, using the appropriate work gloves can dramatically reduce hand injuries. One solution, designed and developed to help employees select the correct glove for the task, is the Boart Longyear Glove Matrix. The Glove Matrix clearly sets the guidelines for what glove to use and when to use them. Read the article and download Boart Longyear’s Glove Matrix.

In August, Senior Engineer Andrew Salisbury wrote about the MDR500 rig’s success. This mobile underground diamond drill rig was designed exclusively for Boart Longyear Drilling Services. It leverages the upcoming LMi power and control interface and comes equipped with 500m of on-board rod storage (NQ rods) making it a self-sufficient mobile drill rig.

The MDR500 was the long-term brainchild of Geoff Moroney (Drilling Services Asia Pacific Fleet & Asset Manager) and John Kirkwood (Drilling Services Asia Pacific Regional Director). The project was given the go-ahead in the third quarter of 2016 aftermarket research indicated that there was a desire from sections of the Australian market for a medium depth underground diamond drill rig which was in the most part self-sufficient and could move quickly from hole to hole.

In this article, Anthony Markham, Senior Product Designer of Capital Equipment, describes the challenge Boart Longyear’s Drilling Services faced with moving existing StopeMaster equipment safely and quickly through a mine. With the combined dedication of many remarkable Boart Longyear employees around the world, the team started engineering a new StopeMaster MDR rig that would solve the issues the mining company was experiencing.

The newly commissioned StopeMaster MDR rig solved the issues of moving the StopeMaster, making moves from stope to stope faster and requiring less time and resources from the mine. The StopeMaster MDR equipment is also safer with rod handling capabilities and semi-autonomous drilling with a new LMi control panel which controls both the rod handler and the StopeMaster MDR rig. Check out this article and download the Drilling Services Overview to learn more about Boart Longyear Drilling Services capabilities, fleet, safety programs, and drilling methods and applications.

Is a career in drilling right for you? In this article, the challenges of drilling are discussed, and key factors are considered when researching jobs in the drilling and mining industry. For example, at drill sites, a certain level of physical fitness is required for employees to adequately carry out their tasks. Working on a drill rig involves labor-intensive activities such as heavy lifting and manual handling.

A career in drilling is an important decision for both employees and their families. Individuals who work in drilling enjoy work that is often physically demanding in challenging conditions. But they’re also aware of the great benefits and rewards of this industry. If a career in drilling seems like a good fit for you, this article is a must-read.

In June, Global Product Manager Zac Strauss discussed the most important factors when considering a new drill rig purchase. Buying a new drill rig is a big decision and many variables and factors affect that decision. The biggest question one has to answer is, “Will this drill rig make money? Or cost more to own than some other option that can accomplish the same for less?”

It’s important to take time to consider options. Evaluate current drill rig fleet and consider what it will take to get everything maintained and updated to be competitive. Does your drilling rig take advantage of recent innovations and meet the latest safety standards? If repairs and available parts outweigh returns, look at updating your fleet. The number one reason to buy new equipment versus used equipment is to enhance productivity, improve safety, and enjoy long-term reliability.

Since 1890, Boart Longyear has been transforming the drilling industry with innovations like the wireline for faster core retrieval, dual-tube flooded reverse circulation drilling, and sonic drilling for mining applications. This article focuses on the LR500, a drill rig built specifically to meet the increasing needs for deeper dewatering wells for Nevada mining.

Check out this article to discover the distinct features of the LR500 such as the size and weight of the casing, how it’s electrically powered, and its automated drilling features. Also be sure to download the Drilling Services fleet depth chart to discover the wide range of services Boart Longyear provides.

In February, Chris Lambert, Senior Product Manager, discusses different factors that affect the way drilling could be affecting bits. The best way to save money on consumables like bits is to check drilling methods. In this article, these simple tips could decrease operating costs and add more cash to the bottom line.

Quick tips are also included, which give insight into rotational speed, weight on bits, torque, penetration rate, water flow, and sharpening. You can also download the Diamond Products Catalog to explore the full range of diamond bits Boart Longyear offers.

John Roberts, Professional Geologist and Commercial Manager for Boart Longyear, describes the complexities of designing and planning a drilling project. There are many risk factors which need to be considered in order to mitigate issues that could impact productivity and/or budget, ultimately impeding the success of the project.

This article addresses considerations and common pitfalls in drill pad planning, which is critical to the mobilization of the drills and crews that will complete your carefully designed drilling project. The first thoughts should be “what purpose is the hole, and what type of drilling will be performed.” Make sure to download the recommended drill pad layouts!

As we move into 2019, you can look forward to additional case studies, interesting and complex drilling projects, tips and tricks, and how-to articles. We are working hard to bring you the content that makes a difference and makes your life a little easier. Thank you for reading INSITE and engaging with Boart Longyear. We couldn’t do any of it without all of you! Wishing all of you a successful and prosperous 2019!

If you have any questions or feedback, we would love to hear from you! You can leave comments below by clicking to expand on the icon and word DISCUSSION.

Our host, Jon Peterson (Geo Jon for fun), works for the Products division as a Customer Service Representative. Jon graduated from the University of Utah in 2015 with his Bachelors of Science in Geology. He’s worked for Boart Longyear for the last two and a half years and interned as a geologist with an exploration company for about six months prior to coming to work for Boart Longyear. Jon has been married for a year and a half and in his free time enjoys trail running, hiking, working on his yard, spending time with family, and playing with his black lab Dexter. 

We would love to hear your questions and comments below. Thanks for listening and if you liked this episode, share it on LinkedIn, Facebook, or Twitter. 

Zac has a bachelor’s degree in materials science and engineering and a master’s degree in business administration. He started at the company in 2006 as a new product development engineer in diamond drilling products. He’s held other roles such as product manager for capital equipment spares and operations manager for aftermarket and fleet maintenance. He has been in his current role as product manager, capital drilling equipment since 2015.

Our host, Jon Peterson (Geo Jon for fun), works for the Products division as a Customer Service Representative. Jon graduated from the University of Utah in 2015 with his Bachelors of Science in Geology. He’s worked for Boart Longyear for the last two and a half years and interned as a geologist with an exploration company for about six months prior to coming to work for Boart Longyear. Jon has been married for a year and a half and in his free time enjoys trail running, hiking, working on his yard, spending time with family, and playing with his black lab Dexter. 

Read the full article and download the Drill Rig Service Interval Checklist

We would love to hear your questions and comments below. Thanks for listening and if you liked this episode, share it on LinkedIn, Facebook, or Twitter. 

The frictional heating is the result of ‘rubbing’ contact or ‘drag’ against a mating surface. Friction heat can build to exceed the transformation temperature of the steel (or ‘austenite transformation start temperature’, ~750degC/1350degF), followed by rapid cooling from surrounding steel or cooling fluid, hardening, and embrittlement. When this cycle repeats frequently, the heating and cooling create rapid expansion and contraction which leads to fatigue failure, seen as perpendicular cracks that propagate from the surface.  

Figure 1 – Oil & Gas Tool Joint with heat check hardening and cracking

While this phenomenon is well documented in engineering texts, the problem has been prominent in the oil and gas exploration industry since the 1940’s. The API (American Petroleum Institute) describes heat check cracking as, “Formation of surface cracks formed by the rapid heating and cooling of the component” (API ‘RP 7G-2, Recommended Practice for Inspection and Classification of Used Drill Stem Elements’, and ‘RP 96, Deepwater Well Design and Construction’.)

A 1992 IADC/SPE paper on heat check cracking described full-scale simulations to prove that the heating and hardening are easily achieved, but that fatigue cracking only results from the rapid heating and cooling associated with each rotation of the drill string.

As shown in these pictures of wireline coring drill rods, heat check cracking can actually be easily identified, visually in the field. Heat check cracks are unique in that they follow the axis of the rod (longitudinal or ‘axial’ orientation), and are located near the female or box end shoulder, and are associated with a shiny, polished wear area. This section of the box always protrudes slightly more than any other area on a wireline drill rod and grows or ‘bulges’ under high drilling loads.

‘Box bulging’ is the result of a) the interference fit between the pin and the box (which is responsible for keeping the joint closed under deceleration ) and, b) the compression of the box shoulder under torsion and any radial loading from the thread-form. The positive load flank angles of traditional thread-forms, such as Q threads, generate radial load components that can increase box bulging to the point of separation, whereas premium thread forms with reverse-angle load-flanks, such as RQ and XQ, actually limit box bulging.

Since heat check cracks are the result of fatigue loading, they always start from the surface and form perpendicular to the direction of the expansion and contraction which is longitudinal or axial on a drill rod and easily pass across turns of thread. Fatigue failures that result from excessive drilling loads or excessive deviation always produce cracks that start internally and form perpendicular to the axis, or circumferentially, and typically follow the thread. In other words, since there are no drilling loads that act circumferentially, the only way to form longitudinal or axial cracks is through rapid heating and cooling.

Also, consider that the fatigue strength of any steel is less than only 50% of its normal ‘yield strength’ and that hardened steel is much more brittle than tempered steel. When subjected to excessive fatigue loading, the maximum expected life of any steel is less than three million cycles of alternating load. In terms of a spinning wireline drill rod, this represents less than a few days operation—at most. This same material limitation is behind fatigue failures in drill rod joints when subjected to excessive deviation (refer to our earlier article, “Drill Rod Bending Capabilities and deviated hole applications).

These limitations hold true for all wireline drilling industry carbon and alloy steel grades, all tube forming processes, all parallel and variable wall tubing, and all heat treatment configurations. This is because the transformation temperature is determined by carbon content, and does not worsen significantly without abnormally high levels of carbon (for example, the grade AISI/SAE 1541 has excessive carbon and a reduced transformation temperature, which was a common grade before heat treatment became popular). Also, whether a drill rod was initially heat treated or not, steel will transform when frictionally heated above its critical temperature, regardless of previous material properties.

Figure 2 – Various wireline coring drill rod samples with heat check hardening and cracking

Further, these material limitations hold true regardless of whether a drill rod is new or used, i.e. transformation properties do not change with use.  Operators who suffer from heat check cracking often claim to have older rods that did not crack, which is just a coincidence. That is to say, whether or not a heat check cracking incident occurs depends on a difference in the loading – possibly in the same hole – rather than any difference in the drill rods.

In summary, ‘heat check cracking’ is the result of an application issue where there is heat generated by a) lateral contact pressure and, b) insufficient lubrication, leading to fatigue failure.

Lateral contact pressure, or ‘drag’, can obviously be created with a misaligned drill rig or when the drill rod string passes through a deviation, but more typically is associated with drill string buckling, due to excessive drilling torque, rotational speed, and thrust or ‘weight on bit’. A reduction in any of these operating parameters will reduce the lateral contact pressure. However, in some cases drill rod midbodies may have been permanently twisted or ‘bent’, due to dynamic overload or due to roller rod handlers, which adds to lateral contact pressure. Always minimize fatigue and lateral loading by limiting hole deviation “dog-legs” (total deviation in dip and azimuth) to less than 1 degree per rod length, monitoring with tight hole survey intervals, and corrective reaming operations (limit to less than 0.6deg per rod in larger diameter holes). Avoid dynamic loading and rod twisting by maximizing spacing between multiple deviations and by eliminating neighboring deviations with opposing or divergent directions. Alternatively, select a free-cutting drill bit which will allow for reduction in torque and thrust. Use a Boart Longyear shoulder thickness wear gauge to inspect for un-even wear around the box shoulder circumference, which can provide an early warning to adjust operating parameters or improving lubrication.

It is helpful to apply and maintain an appropriate lubricant or grease coating on the outer surface of the drill string which can directly reduce the friction factor and the heat generated. During rod pulls, visually inspect how the coating has worn away as a good indicator of the degree of lateral contact. ‘Shiny one-sided’ wear patterns, either at the box ends or with a ‘slow’ one-quarter spiral turn over the rod length, indicate excessive loading.

While drilling fluids contribute to heat check hardening by quenching heated surfaces, maintain a high fluid pressure and consider polymer additives to improve lubrication, and reduce frictional heating and quench severity.

Finally, consider this recommendation from the IADC/SPE, “When users are confronted with the cause of failure, the initial reaction is often disbelief…It is difficult to believe that tool joints can be heated above their critical temperature while drilling…in the presence of mud circulation. From time to time, knowledge of the in-hole friction heating and cyclic quenching phenomena and characteristic longitudinal cracks need to be reintroduced to the field. Users and inspectors need to recognize the evidence and cull out the affected joints.”

A lot of drilling companies run every drill rig part to failure. Meaning, they don’t replace anything on the drill rig until it fails. At the other end of the spectrum, a truly preventive maintenance program replaces parts on a fixed and planned interval regardless of wear or condition of the part. When following one or the other, neither of these philosophies is necessarily the most cost-effective philosophy. Running parts to failure can cause minor or major breakdowns. And it goes without saying, any breakdown, small or significant, costs money – lost productivity, jeopardizing up-time contractual obligations, and lost drilling time waiting for replacement parts.

Sonic head water swivel

Even though planning is critical, a strictly preventive maintenance program also costs more by replacing parts regardless of condition and leaving some life of that part on the table. And just because the engine is running (typically gauged by service hours) – not all components are exposed to the same amount of wear. Some components are used more frequently depending on the type of drilling and the size and type of the borehole. Additionally, environmental factors can affect the wear on components and parts including the weather, dust, sand, cuttings, wet, damp, salty, atmospheric conditions (high and low elevations affect air density and can impact how components perform, age, and fail), and ground conditions are all factors affecting drill rig components. Taking it all into consideration, the life of different components can vary greatly.

While regular and routine maintenance is important and definitely helps reliability, it can still be easy to miss tell-tale signs of wear and critical upcoming replacements. Replacing parts before running them to failure can help avoid larger breakdowns and costly downtime. We recommend frequent, planned inspections in place of a comprehensive preventive-only maintenance program where parts are replaced before they fail. A drill rig maintenance program of regular inspections, planned preventive maintenance, and scheduled major maintenance/overhauls is the better way to lower and manage your cost of ownership and keep your machines running and drilling reliably.

If you are not already doing it, a condition based preventive maintenance program based on frequent visual inspections can be implemented with the right checklists and change management processes for your field employees. Develop a routine for drill rig inspections or audits using standardized checklists as a guide to check condition and identify parts showing wear and near end of life. Next, the report is used to build a list of parts so you can place component orders and plan for downtime to maintain your rig.

Taking the time to do an assessment to prepare, order, and plan for any future maintenance is the most cost-effective method to get the most out of your long-term assets.

The key is taking the time to do an assessment of the condition of the rig, on a regular basis. Depending on the type of rig, the type of drilling, and up-time contractual obligations, you can schedule a mechanic to visit the rig on site, keep a mechanic on call, or take the drill rig back to the shop for major repairs/regular overhauls.

Sonic oscillating weights for LS600 sonic drill head

Sonic oscillation weights for LS250 MiniSonic head

Boart Longyear uses its technical services group to keep its drill rigs running and can send our technical services group out to your site or shop to do drill rig assessments. The two goals of any drill rig assessment are to:

1. Identify what is damaged or wearing out.

2. Build a recommendation to include the required parts to order and when and where (onsite or in a workshop) repairs need to be performed.

Boart Longyear’s Drilling Services has daily, weekly, and monthly inspection checklists for all drill rigs. Checklists for regular drill rig inspections doesn’t need to be specific to the drill rig, you can use a general checklist that applies to all rigs.

To make it easier for our customers, there is a comprehensive spare parts list for every Boart Longyear drill rig in the Service and Parts Information Network (SPIN). SPIN is a real-time, online, drill rig parts catalog so you can view and find genuine Boart Longyear parts and drill rig manuals, access interactive drill rig diagrams, and view parts manuals. SPIN also makes it easier to search and find the parts you need for your next service interval. Visit https://www.boartlongyear.com/product/spin/ to register to access SPIN today.

As the world’s leading drilling products and services provider, Boart Longyear understands how spare parts and service availability is critical to the success of a drilling operation. Consider us your partner in keeping your projects running, with lower operating costs and higher returns on your equipment investments.

Boart Longyear rigs are designed to meet demanding conditions. Boart Longyear genuine parts are engineered, manufactured, and selected to also meet demanding conditions. With genuine parts, you know you’re receiving parts that are specifically designed and engineered for that purpose, along with Boart Longyear’s global strategy and support.

Robert Jex started working in the drilling industry 35 years ago as a driller assistant. Now, Robert oversees the coring division in the US and Mexico. Working for Boart Longyear for the past 30 years, Robert has experience in both surface and underground operations here in the US and globally.

On this episode, Robert discusses the importance of quality core, how things can sometimes go wrong when retrieving core, the impact, and some troubleshooting tips for core recovery.

Learn more about Surface Coring Drilling Services

We would love to hear your questions and comments below. Thanks for listening and if you liked this episode, share it on LinkedIn, Facebook, or Twitter.